Garrett Catalog

performance products
contents
General Information
Welcome.....................................................................................1 History ........................................................................................2 Whats New .................................................................................3
Applications & Distributors

Applications................................................................................4 Performance Houses .................................................................5 Engineering Houses ...................................................................6 Master Distributors ....................................................................7
Turbochargers
Power/Displacement Chart ........................................................8 GT12............................................................................................9 GT15..........................................................................................10 GT20..........................................................................................11 GT22..........................................................................................12 GT32..........................................................................................13 GT35..........................................................................................14 GT37..........................................................................................15 GT40..........................................................................................16 GT42..........................................................................................17 GT60..........................................................................................18 Additional Models .....................................................................19
Ancillary Products
Wastegate.................................................................................20 Blow-off Valve ..........................................................................21 Intercoolers ........................................................................22-23
Technical Information
Tech Info .............................................................................24-25 Testing.................................................................................26-27 Statement of Warranty.............................................................28
Appendix
..................................................................................................a.I
General information
welcome
The Garrett Performance Products Catalog

elcome to the new Performance Products Catalog!
You are about to encounter some of the most innovative turbochargers in the industry today. Whether it is the advanced aerodynamic wheel design or our enhancement of the GT product line, you will see many exciting turbocharging additions within this catalog. One of the most evident modifications to our catalog has been the name itself. The Ballistic Concepts title has been changed to reflect our renewed emphasis on performance, and so all future product introductions will be under the Garrett Performance Products title.
Here are some more reasons to investigate the Garrett Performance Products Catalog:
"The catalog design approach - our team has uniquely modeled this catalog to provide all turbocharger information on one page in an easy to interpret manner. "Application flexibility - kits are now being offered to allow you to choose the optimal turbocharger for your individual application and provide you the flexibility to upgrade now or in the future. Mixing and matching has never been easier! "Turbine maps! The Garrett team is thrilled to be the first to provide ALL of the data necessary to ensure the best performance for your vehicle! "Garrett is where you want to be! We have engineering teams on 5 continents that are continually innovating to bring the most up-to-date technology to the industry. And, with some of the most rigorous functional testing in the field you know you are buying the superior product. The Garrett Aftermarket team has a lot in store for the future, so this catalog design will allow for the addition of product pages and other information as we grow our performance product line - so stay tuned for further updates!
-The Garrett Performance Team
"
We are also interested in hearing about your turbocharging opportunities, so please feel free to drop us a line at garrett.performance@honeywell.com.
History
Garrett is the leading innovator of turbochargers in the world, providing engine boosting systems that save fuel and reduce emissions while providing an increase to engine performance.
Garretts turbocharging business traces its roots to an aerospace company established in California by entrepreneur Cliff Garrett. Over time, the turbocharging business spun off to establish itself as a serious player in the engine boosting industry. Through names such as AiResearch, AlliedSignal, and the Honeywell of today, Garrett has sustained its reputation for innovating turbocharger technologies generation after generation. From its long list of industry firsts to its leading-edge ball bearing turbos for racecars, Garrett develops and manufactures the same cutting-edge boosting expertise that goes into all Garrett products. Most of the worlds top engine and car manufacturers employ Garrett turbochargers to boost their engines, and with 27,000 turbos produced EVERY DAY you know the Garrett name is one you can trust. Finally, through the Garrett network of Master and Performance Distributors listed on the next page, Garretts turbocharging product line is readily available in the aftermarket for you to install on your vehicle!
What's new
Meet Garretts Newest Technologies
Looking for an efficient, reliable turbocharger that can handle higher boost pressure? Your search ends with the new Garrett Performance Products Catalog. As the industry leader in turbocharging innovation, Garrett turbochargers incorporate the latest advances in boosting technology and aerodynamic design. Whether youre looking to install a new turbocharger or need to upgrade an existing one, youve come to the right place.
Garretts newest turbocharger line delivers these benefits and more over our competitors:
"Improved Efficiency New, efficient turbine stages deliver more power to your engine and allow Garrett turbochargers to spool up faster than ever. Garrett engineers have eliminated old efficiency killers, including on-center turbine housings*, clipped turbine wheels, and antiquated aerodynamics with the new GT product line. "Increased Boost Capacity Garretts new turbochargers feature compressor wheels that can handle a higher boost pressure. So go aheadincrease the PSI. Your Garrett turbocharger can take it! "True Ball-Bearing Turbochargers Thanks to our single-cartridge ball-bearing technology, Garrett turbochargers generate far less frictional drag and are 10 times more durable than traditional journal-bearing turbochargers. While first developed for racing, over 100,000 ball-bearing turbos have been produced for OE applications, and are now available in a range of sizes for the street. "Proven Durability The Garrett engineering team puts our turbochargers through more than 20 durability and performance tests before they reach consumers. And since Garrett is the global leader in manufacturing turbochargers, producing more than 7.1 million units every year, you can be assured a Garrett turbo is a dependable one.
* See Turbo Terms in Appendix
Applications & Distributors

Applications
Garrett Applications
Garrett Performance Houses provide a wide range of applications using Garrett turbochargers, cartridges, and component parts.
Make
Audi
Model
1.8L
Performance Specialist
Audi Performance Racing Innovative Turbo Systems Tial Products Tial Products Innovative Turbo Systems Limit Engineering Precision Turbo & Engine Lingenfelter Advanced Turbo Systems BD Power Advanced Turbo Systems Gale Banks Engineering Precision Turbo & Engine Lee Performance Products Limit Engineering Precision Turbo & Engine Edelbrock Callaway / Mazda Speed Jim Wolf Technology Turbo Engineering Corp. Tial Products Turbo Engineering Corp. Tial Products Turbo Engineering Corp. Innovative Turbo Systems Tial Products
S4, A6 Buick Grand National
Chevrolet Dodge
Corvette, Camaro, Light Duty Truck 5.9L Light Duty Truck
Ford/Navistar
6.9L, 7.3L - Light Duty Truck Focus Mustang
Honda Mazda Nissan
Civic Protg 300ZX, Sentra, 240
Porsche Subaru
911, 944 Imprenza WRX
Toyota Volkswagon
Pickup, 4 Runner, Supra 1.8L - Golf, Passat, Jetta, Beetle
distributors
Performance houses
Garrett Performance Houses supply upgrade and hybrid turbochargers, Garrett component parts for a wide variety of turbocharger models, and the expertise to repair and rebuild the Garrett line of Performance Turbochargers.
Lee Performance Prod., Inc. 555 Birch Street Lake Elsinore, CA 92530 909-674-8171 909-245-6883 (fax) sales@leeperformanceproducts.com www.leeperformanceproducts.com Turbonetics Inc. 2255 Agate Court Simi Valley, CA 93065 805-581-0333 805-581-1913 (fax) info@turboneticsinc.com www.turboneticsinc.com T.E.C. Turbocharger Engineering 17222 S. Golden Road Golden, CO 80401 800-950-8872 303-271-3927 (fax) jlatour@turboengineering.com www.turboengineering.com Hypermax Engineering, Inc. 255 East Route 72 Gilberts, IL 60136 847-428-5655 847-428-5682 (fax) hypermax@ais.net www.cl.ais.net/hypermax/index.htm Limit Engineering 885 Kiowa Ave. Lake Havasu City, AZ 86406 928-453-7321 928-453-0789 (fax) craig@redrivernet.com www.limitengineering.com Precision Turbo & Engine Rebuilders 616A South Main Street PO Box 425 Hebron, IN 46341-8904 219-996-7832 219-996-7749 (fax) turbo@netnitco.net www.precisionte.com Innovative Turbo Systems 845 Easy Street, Unit 102 Simi Valley, CA 93065 805-526-5400 802-526-9240 (fax) rick@innovativeturbo.com www.innovativeturbo.com Turbo & Electric 2408 Grand Avenue Phoenix, AZ 85009 602-253-6817 602-253-6841 (fax) turboguy@swlink.net
distributors
Engineering Houses
Garrett Engineering House accounts provide the performance market with retro fit turbocharger kits, complete systems and upgrade turbochargers.
Ford, GM & Dodge Trucks

Advance Turbo Systems, Inc. 5919 South 350 West Murray, UT 84107 801-263-0900 801-265-1253 (fax) ats@xmission.com www.atsturbo.com Gale Banks Engineering 546 Duggan Avenue Azusa, CA 91702 800-483-7693 626-334-1743 (fax) sales@bankspower.com www.galebanks.com BD Brake Unit A10-33733 King Road Abbotsford, BC V2S 7M9 800-887-5030 604-853-8749 info@bd-power.com www.bd-power.com
GM
Lingenfelter 1557 Winchester Road Decatur, IN 46733 260-724-2552 260-724-0422 (fax) sales@lingenfelter.com www.lingenfelter.com
Audi & Volkswagon

TIAL Products 510 S. Washington, Suite 16 Owosso, MI 48867 989-729-8553 517-729-9973 (fax) tialinc@earthlink.net www.tialsupport.com Audi Performance Racing 1027-B Opelika Road Auburn, AL 36830 800-680-7921 334-502-5180 (fax) brett@goapr.com www.goapr.com Advanced Tuning Products 44777 South Grimmer Blvd. Fremont, CA 94538 510-445-1682 510-445-1692 (fax) info@vwturbo.com www.vwturbo.com
Honda
Edelbrock Corp. 2700 California Steet Torrance, CA 90503 310-781-2222 310-320-1187 (fax) edelbrock@edelbrock.com www.edelbrock.com
Nissan
Jim Wolf Technology 212 Millar Ave. El Cajon, CA 92020 619-442-0680 619-442-8160 (fax) jim@jimwolftechnology.com www.jimwolftechnology.com
distributors
Master Distributors
Garrett Master Distributors supply the market with the complete offering of the Garrett Aftermarket product line.
ADP Distributors Inc. (Canada) 105-18935 9th Avenue Surrey, BC CANADA V4N3P3 800-663-6308 604-888-5389 (fax) rgw@adpdist.com www.adpdist.com ADP Distributors Inc. (USA) 18854 72nd Avenue South South Kent, WA 98032 800-663-6308 425-656-1571 (fax) cek@adpdist.com www.adpdist.com Area Diesel Service Inc. North on University Carlinville, IL 62626 800-637-2658 217-854-8972 (fax) ads@areadiesel.com www.areadiesel.com
Central Motive Power, Inc. 6301 North Broadway Denver, CO 80216 800-822-4332 303-428-6785 (fax) gpsmith@centralmotivepower.com www.centralmotivepower.com D&W Diesel & Electric 1508 Clark Street Road Auburn, NY 13021 315-253-7740 315-282-0031 (fax) r.banas@dwdiesel.com Diesel Injection & Electric Co. 231 Main Street Forest Park, GA 30297 800-241-4389 404-361-1701 (fax) dinjection@mindspring.com
Diesel Injection Service Co., Inc. 4724 Allmond Avenue Louisville, KY 40209-0389 502-361-1181 502-364-3200 (fax) tombrown@dieselusa.com Magneto & Diesel Service 6931 Navigation Boulevard Houston, TX 77011 800-392-5517 713-928-8154 (fax) tingram@mddistributors.com www.mddistributors.com
Turbochargers
Turbochargers
11.0
10.0
9.0
8.0
GT60
7.0
Displacement
6.0
GT42
5.0
4.0
GT40
3.0
GT35 GT32 GT20 GT22 GT15 GT12

0 100 200 300 400 500
GT37
2.0
1.0
600
700
800
900
1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100
Power
GT12
1.417
GT12 41mm, 50 trim, 0.33 A/R
Pressure Ratio (t/t) P2c/P1c
2.5
75%
GT12, 72 trim, 0.39 A/R

Corrected Gas Turbine Flow (lb/min)
10 8 6
1.5
1
4 2 0 1.00
10
15
20
25
Turbine 59% Max Efficiency

1.50 2.00 2.50 3.00 3.50
Corrected Air Flow (lbs/min)
Pressure Ratio (T/s) P1T /P2S
Powershift
3.126 2.669
Horsepower 50 - 130 Displacement .4L - 1.2L
1.811
C O M P R E S S O R
T U R B I N E
Turbo
CHRA 708247-7
Wh Dia 41mm
Trim 50
A/R 0.38
Wh Dia 35.5mm
Trim 72
A/R 0.43
Type Wastegated
GT12
708001-1
GT15
3.259 3.413 2.047 1.969
GT15 45mm, 60 trim, 0.48 A/R

2.8 2.6 2.4 2.2 2 1.8 1.6
75% 74% 72% 70% 68% 65%
GT15, 72 trim, 0.35 A/R

10 8
1.4 1.2
6
1
4 2 0 1.00 1.50 2.00 2.50
10
15
20
25
Turbine 59% Max Efficiency

3.00 3.50
Powershift
2.874 1.575
Horsepower 100 - 220 Displacement 1.0 - 1.6L
C O M P R E S S O R
T U R B I N E
Turbo
CHRA 431876-93
Wh Dia 45mm
Trim 60
A/R 0.48
Wh Dia 41.2mm
Trim 72
A/R 0.35
Type Wastegated
GT15
466755-3
10
GT20
1.969 2.904 3.543
GT20 56mm, 55trim, 0.53 A/R

3 2.8
2.008
2.6
2.4 2.2
78%
2 1.8 1.6 1.4 1.2

79%
76% 74% 72% 70% 68% 65%
GT20, 72 trim, 0.46 A/R

14 12 10 8 6 4 2 0 1.00 1.50
1 0 5 10 15 20 25 30 35
Max Efficiency 66%

2.00 2.50 3.00

1.575
Powershift
2.874
C O M P R E S S O R
T U R B I N E
Turbo
CHRA 433289-96
Wh Dia 56mm
Trim 55
A/R 0.53
Wh Dia 47mm
Trim 72
A/R 0.46
Type Wastegated
GT20
454126-2
11
GT22
2.362
GT22 52mm, 60 trim, 0.51 A/R GT22 59.4mm, 52 trim, 0.42 A/R
3.2
4.055 3.543 2.756
3 2.8
1.575
2.6 2.4 2.2 2

74% 76% 74%
2.874
1.8
58%
GT22, 72 trim, 0.67 A/R GT22, 72 trim, 0.56 A/R

20
1.6 1.4 1.2
80%
58%
15
1 0
10
10
15
20
25
30
35
0 1.00 1.50
Max Efficiency 72%

2.00 2.50 3.00
Powershift
C O M P R E S S O R
T U R B I N E
Turbo
CHRA 451298-6 451298-9
Wh Dia 52mm 59.41mm
Trim 60 52
A/R 0.51 0.42
Wh Dia 50.3mm 50.3mm
Trim 72 72
A/R 0.67 0.56
Type Wastegated Free Float
GT22
452187-6 452214-3
T U R B I N E
O P T I O N
436313-6 451503-1
72 72
0.67 0.56
Wastegated Free Float
12
3.386
GT32
1.752 2.000 3.937
4.156
4.493
GT32 71mm, 52 trim, 0.52 A/R

3.4 3.2 3
2.750
2.8 2.6 2.4

75% 72% 70% 74% 68% 65% 60%
2.2 2 1.8 1.6 1.4 1.2 1

0 5 10 15 20 25 30 35 40
GT32, 73 trim, 0.78 A/R GT32, 73 trim, 0.69 A/R

24 20 16 12 8 4 0 1.00 1.50
45
Max Efficiency 68%

2.00 2.50 3.00
Powershift
Horsepower 200 - 420 Displacement 2.0 -2.7L
C O M P R E S S O R
T U R B I N E
Turbo
CHRA 436058-3
Wh Dia 71mm
Trim 52
A/R 0.5
Wh Dia 64mm
Trim 73
A/R 0.78
Type Wastegated
GT32
452203-1
T U R B I N E
O P T I O N
451225-26 435066-32
73 73
0.78 0.69
Free Float Wastegated
13
GT35
2.756 4.213
GT35 71mm, 52 trim, 0.50 A/R GT35 76mm, 52 trim, 0.50 A/R
3.6 3.4
4.465
2.00
3.937
3.2 3.0
2.8 2.6 2.4

68% 75% 72%
2.750
3.250
77%
72%
2.2
68%
2.0 1.8 1.6
GT35, 84 trim, 1.18 A/R GT35, 84 trim, 1.05 A/R GT35, 84 trim, 0.94 A/R GT35, 84 trim, 0.67 A/R
40 35 30 25 20 15 10 5 0 1.00
1.4 1.2 1 0 10 20 30 40 50 60
Powershift
Max Efficiency 71%
1.50 2.00 2.50 3.00 3.50
Horsepower 260 - 510 Displacement 2.5L - 3.2L
C O M P R E S S O R
T U R B I N E
Turbo
CHRA 436058-11
Wh Dia 71mm
Trim 52
A/R 0.6
Wh Dia 68mm
Trim 84
A/R 1.18
Type Free Float
GT35
731413-1
C O M P R E S S O R
O P T I O N
T U R B I N E
O P T I O N
731428-1
76mm
52
0.5
714690-13 700889-3 700889-15
84 84 84
1.05 0.94 0.67
Free Float Free Float Free Float
14
GT37
2.362 4.000 3.937
GT37 76mm, 52 trim, 0.54 A/R GT37 82mm, 52 trim, 0.54 A/R TO4 Housing 76mm, 52 trim, 0.70 A/R
3.5
1.752
5.673
3.287
2.5
77% 76%
74% 60%
3.386
60%
60% 78% 74% 74%
GT37, 84 trim, 1.12 A/R

40 30 1 20 10 0 10 20 30 1.5
40
50
60
Corrected Air Flow (lbs/min) Max Efficiency 68%

0 1.00 1.40 1.60 2.20 2.60 3.00
Powershift
C O M P R E S S O R
T U R B I N E
Turbo
CHRA 436085-1 436085-5
Wh Dia 76mm 82mm
Trim 52 52
A/R 0.54 0.54
Wh Dia 72.5mm 72.5mm
Trim 84 84
A/R 1.12 1.12
Type Free Float Free Float
GT37
452159-1 452159-3
C O M P R E S S O R
O P T I O N
731428-2 731428-3
76mm 82mm
52 52
0.7 0.54
15
GT40
2.559
4.2 4
4.646
3.8 3.6
5.074
3.315
3.4 3.2 3 2.8 2.6 2.4 2.2 2 1.8 1.6 1.4 1.2 1 0 10 20 30 40 50 60 70
78% 78% 76% 76% 65% 65%
2.750
3.500
GT40, 84 trim, 1.34 A/R GT40, 84 trim, 1.19 A/R GT40, 73 trim, 0.94 A/R
40 30 20 10
Max Efficiency 70%

0 1.00 1.40 1.60 2.20 2.60 3.00
Powershift
C O M P R E S S O R
T U R B I N E
Turbo
CHRA 449739-10 449739-12
Wh Dia 82mm 88mm
Trim 50 54
A/R 0.58 0.72
Wh Dia 77mm 77mm
Trim 73 84
A/R 0.94 1.34
GT40
452232-5 703457-1
T U R B I N E
O P T I O N
434309-88
84
1.19
Free float
16
GT42
4.213
Powershift
Horsepower 500 - 1000 Displacement 4.4L - 6.5L
50 40 30 20 10 0 1.00
5.0 4.8 4.6 4.4 4.2 4 3.8 3.6 3.4 3.2 3 2.8 2.6 2.4 2.2 2 1.8 1.6 1.4 1.2 1 0 20 40
74% 78%
77% 74%
Max Efficiency 69%

1.50 2.00 2.50 3.00 3.50
60
80
100
C O M P R E S S O R
T U R B I N E
Turbo
CHRA 712402-7 712402-8
Wh Dia 94mm 102mm
Trim 56 53
A/R 0.6 0.6
Wh Dia 82mm 82mm
Trim 84 84
A/R 1.15 1.15
GT42
731376-1 731376-2
T U R B I N E
O P T I O N
448925-12*
5.000 4.831
84 84 84
1.28 1.15 1.01
Free Float Free Float Free Float
448925-13* 448925-14*
5.921
5.345
Ball Bearing CHRA Options

2.750
451888-9
4.440
94mm 102mm
56 53
82mm 82mm
84 84
451888-11
17
* future product addition
GT60
6.000 6.156
GT60 141mm, 56 trim, 1.05 A/R

5.0 4.8
10.381
4.480
4.6 4.4
4.250
2.750
4.2
4.440
3.8 3.6 3.4 3.2 3 2.8 2.6 2.4 2.2 2 1.8 1.6 1.4 1.2 1 0 50 100 150 200
79% 76% 72%
120 100 80 60 40 20
Corrected Air Flow (lbs/min) Max Efficiency 79%
0 1.00
1.50
2.00
2.50
3.00
3.50
Powershift
Horsepower 1450 - 2000 Displacement 6.2L - 10L
C O M P R E S S O R
T U R B I N E
Turbo
CHRA 730496-1
Wh Dia 141mm
Trim 56
A/R 1.05
Wh Dia 130mm
Trim 84
A/R 1.47
Type Free Float
GT60
731377-1
T U R B I N E
O P T I O N
441319-97
84
1.25 A/R 1.70 A/R
Free Float Free Float
441319-95* 84
18
* future product addition
Additional Models
In addition to the GT products contained in the 2002 Garrett Performance catalog, Garrett provides coverage for a broad selection of traditional turbocharger models. These models are serviced with two product segments. Component Parts The component product segment provides the ability to service and/or make available component parts to Garrett customers who service performance turbochargers that have failed. This product also provides the ability to assemble standard or hybrid turbocharger or cartridge configurations. Traditional Assemblies The traditional assembly product segment is comprised of turbocharger and cartridge assemblies that have been applied to a broad spectrum of existing performance applications. These components and/or assemblies may provide coverage for the following models:
BTG55 BTV75 BTV85 BTW75 T2 T3 T4 T6 T12 T18A T25 T25R
T28 T300 T31 T350 T35R T45 T51 T52 T04 T04B T04E T04S
TA31 TA34 TA45 TA51 TAO3 TB02 TB03 TB22 TB25 TB28 TB34 TB41
TBB25 TBO3 TBO5 TBO6 TBP404 TC43 TC04 THO8A TL75 TL92 TM54 TMF51
TMF55 TP38 TV45 TV51 TV61 TV63 TV70 TV71 TV75 TV80 TV81 TV84
TV92 TV94 TV95 TW41 TW81 UTG75 UTV71 UTV75 UTV94 UTV95 UTW75 UTW83
Contact Your Authorized Garrett Distributor for technical data and product availability.
19
Ancillary Products
Wastegate
High-Performance Stainless Steel Wastegate Assemblies: Garrett Performance Products is pleased to carry TiAl Products 35, 40, and 46mm wastegate assemblies. All wastegate assemblies are constructed with stainless steel valves and valve bodies. Actuator housings are CNC machined billet aluminum, with an optimal actuator to valve ratio of 2.2:1 for maximum flow capacity. The units are also designed with high temperature Nomex diaphragms and oxidation resistant Super Alloy components.
35mm
3.760 IN
40mm
3.769 IN
Valve Size (diameter) 35mm
Part Number 721490-0002 721490-0003 721490-0004 721491-0004 721491-0005 721491-0006 721492-0005 721492-0006 721492-0007
Spring Rate (bar/psig) .36/5.2 .47/6.8 .59/8.6 .55/8.0 .66/9.6 .77/11.2 .60/8.7 .70/10.2 .80/11.6
2.800 IN
4.780 IN
40mm
4.885 IN
46mm
1.575 IN Valve Dia
2.000 IN
46mm
3.976 IN 0.825 IN
5.665 IN
Stainless Steel CNC Wastegate Flanges

1.772 IN
Model 35mm 40mm 46mm
Part Number 776463-0001 776463-0002 776466-0001 776464-0001 716465-0001
Type Outlet Flange Inlet Flange Inlet Flange Outlet Flange Inlet or Outlet Flange
Configuration 2 x thru hole 2 x M8-1.25 4 x M8-1.25 4 x thru hole 4 x thru hole
1.811 IN 1.772 IN
1.772 IN
0.949 IN
2.800 IN
1.994 IN
20
blow-off valve
50mm Compressor Blow Off Valve Assemblies: The Garrett (TiAl) Blow-Off valve design is the result of extensive development and testing. The 50mm compressor bypass valve is a vital component of any turbocharged blow-through induction system. This custom TiAl manufactured blow-off valve will improve throttle (time to boost) response as well as help relieve the damaging effects of compressor surge loading. The CNC machined housings are available in several high luster anodized colors. Note: Blow-off Valve Assemblies include fitting and V-band clamp.
Blow-Off Valve
3.761 IN 0.295 IN
Part Number 714341-0001 714341-0002 714341-0003 714341-0004 714341-0005
Color Red Blue Gray Violet Machined Aluminum
1.969 IN Valve Dia 2.345 IN
2.781 IN
Blow-Off Valve Flange

1.444 IN
Blow-off Valve Flanges

Part Number 722783-0001 722783-0002 722783-0003 Material Aluminum (6061) Steel (1018) Stainles Steel (304L)
2.345 IN
1.875 IN
2.007 IN
21
Intercoolers
The Garrett Performance Intercoolers (also known as Charge Air Coolers) work together with the turbocharger as a part of the total induction system. When air is compressed in the turbocharger it gains a great deal of heat. The heated air has lower oxygen density and therefore is not able to produce as much energy when fed into the cylinders. The job of the intercooler is to remove heat added by compression in the turbocharger and in turn promote more thorough combustion yielding more power, less emissions, and greatly reducing detonation.
Performance estimates made under the following conditions: charge air inlet temperature = 250 degrees F pressure ratio = 2.0 (approximately 14.7psi) cooling air temperature = 75 degree F cooling air flow rate set with 1 in. H2O pressure drop
AIR TO AIR INTERCOOLER CORES (tube-header construction)

A Hot Flow Length (in) 24 26 26.5 30.3 20 B No Flow Length (in) 15.5 18.5 12 16 11 CORE ENVELOPE C Cold Flow Weight Length (in) (lbs.) 2.2 2.8 2.8 2.8 3 29.4 33 15.3 21.8 15.2 Estimated Power (hp) 450 600 400 480 420
Part Number 485257-6001 485643-6003 485740-6002 485980-6002 487085-6002
Charge Air P (psi) 1 0.94 1 0.9 1
Charge Air T (F) 138 142 141 150 119
Effectiveness (%) 79 81 80 86 68
(continued)
22
Intercoolers
AIR TO AIR INTERCOOLER CORES (bar-plate construction)

A Hot Flow Length (in) 16 16 6 8 10 12 14 16 18 24 6 8 10 12 14 16 18 24 24 16 6 8 10 12 14 16 18 24 27.8 B No Flow Length (in) 10.3 5.4 11.7 11.7 12 12 12 12 12 12 12 11.7 11.7 12 12 12 12 12 12 10 12 4. 11.7 11.7 12 12 12 12 12 12.8 CORE ENVELOPE C Cold Flow Weight Length (in) (lbs.) 2.8 2.8 3 3 3 3 3 3 3 3 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 4 4 5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 5 8.8 5 7.1 8 8.7 9.8 10.8 12.6 13.9 18.5 7.3 8.9 10.6 11.8 13.4 15.3 16.4 21.1 25.1 24.4 9.2 11.4 13.3 14.4 16.6 18.5 20.2 26.6 31.4 Estimated Power (hp) 320 205 175 200 225 300 325 350 375 450 150 185 265 300 350 400 465 500 520 400 150 165 225 275 300 345 420 480 575
Part Number 713372-0001 713447-0001 703517-6001 703517-6002 703517-6003 703518-6001 703518-6002 703518-6003 703518-6004 703518-6005 703519-6001 703519-6002 703519-6003 703520-6001 703520-6002 703520-6003 703520-6004 703520-6005 486827-6002 700618-6001 703521-6001 703521-6002 703521-6003 703522-6001 703522-6002 703522-6003 703522-6004 703522-6005 701596-6001
Charge Air P (psi) 0.96 1 0.2 0.29 0.36 0.49 0.57 0.64 0.95 0.79 0.12 0.14 0.32 0.31 0.42 0.52 0.89 1 0.82 0.42 0.1 0.08 0.16 0.17 0.23 0.29 0.45 0.65 0.42
Charge Air T (F) 123 109 92 104 113 115 118 121 126 127 99 104 105 113 115 112 117 127 129 105 90 100 112 120 125 124 120 129 132
Effectiveness (%) 70 62 53 60 65 66 67 69 72 73 57 59 60 65 65 64 67 72 74 60 51 57 64 69 72 71 69 74 76
23
TEchnical Information
Tech info
The following section includes information that is found in several reference books. The Garrett Engineering team is including this information as a quick reference to help you match a Garrett turbocharger to your engine. Examples are incorporated to help walk you through the matching process.
Turbine Maps
1. Turbine Expansion Ratio The degree of exhaust expansion as it passes through the turbine. Example: Exhaust manifold pressure (EMP) = 15 psi Turbine outlet pressure (Outlet P) = 1 psi Atmosphere (Atmos) = 14.7 psi at sea level ER = EMP + Atmos Outlet P + Atmos = 15 + 14.7 1 + 14.7 = 1.89
2. Turbine Corrected Flow The turbine flow is also corrected for temperature and pressure at the turbine inlet (exhaust manifold). Example: Engine air flow (Actual Flow) = 50 lb/min Exhaust manifold pressure (EMP) = 25 psi Exhaust temperature (Gas Temp) = 1500 F Barometric Pressure (Baro) = 14.7 psi Corrected Flow = Actual Flow ([Gas Temp + 460]/519) (Baro + EMP)/14.7 50* ([1500 + 460]/519) (14.7 + 25)/14.7
Corrected Flow =
= 36 lb/min
(continued)
24
Tech info
Compressor Maps:
1. Pressure Ratio Ratio of ABSOLUTE outlet pressure divided by ABSOLUTE inlet pressure. Example: Intake manifold pressure (Boost) = 12 psi Pressure drop, intercooler (PIntercooler ) = 2 psi Pressure drop, air filter (PAir Filter ) = 0.5 psi Atmosphere (Atmos) = 14.7 psi at sea level PR = Boost + PIntercooler + Atmos Atmos PAir Filter 12 + 2 + 14.7 14.7 .5 3. Efficiency Contours The efficiency contours depict the regional efficiency of the compressor set. This efficiency is simply the percentage of turbo shaft power that converts to actual air compression. When sizing a turbo, it is important to maintain the proposed lugline with a high efficiency range on the map. = 2.02 4. Surge Line The surge region, located on the left-hand side of the compressor map, is an area of flow instability typically 2. Corrected Airflow Represents the corrected mass flow rate of air, taking into account air density (ambient temperature and pressure). Example: Air Temperature (Air Temp) = 60 F Barometric Pressure (Baro) = 14.7 psi Engine air consumption (Actual Flow) = 50 lb/min Corrected Flow = Actual Flow ([Air Temp + 460]/545) Baro/13.95 50* ([60 + 460]/545) 14.7/13.95 5. Choke Line The choke line is on the right hand side of the compressor map and represents the flow limit. When a turbocharger is run deep into choke, turbo speeds will increase dramatically while compressor efficiency will plunge (very high compressor outlet temps), and turbo durability will be compromised. = 46.3 lb/min caused by compressor inducer stall. The turbo should be sized so that the engine does not operate in the surge range. When turbochargers operate in surge for long periods of time, bearing failures may occur. PR =
Corrected Flow =
25
Testing
What it takes to become a Garrett Turbocharger!
Do you know what tests your turbo has endured??? Garrett is one of the few turbocharging manufacturers that subjects our turbos to several OE qualification tests. These turbocharging qual tests ensure Garrett produces a safe and reliable turbo for OE applications. When you buy a Garrett turbo you can be sure it is a reliable one!
"On-Engine Durability A 1,000-hour general turbocharger durability test that is run on-engine in one of Garretts engineering laboratories. Some engines die before our turbos do! "Gas Stand Cyclic Durability (aka The Non-Sissy Test) A 500 hour general turbocharger durability test. This is basically a beat the crap out of the turbo test. Survive this one and youve got one tough turbo! "Compressor & Turbine Housing Containment - A compressor/ turbine wheel is weakened to hub burst at a specific speed. No portion of the wheel is allowed to penetrate a containment shroud surrounding the turbocharger. A test to ensure safety. "Shaft Motion - The maximum tolerances of the bearing system are tested for rotordynamic stability beyond the maximum turbocharger operating speed. This means no bearing problems and a long turbo life. "Thrust Bearing Capacity - A test that stresses the thrust bearing at extreme conditions. This test makes sure your Garrett turbocharger can tolerate the load you put it through. "Compressor & Turbine Seal - Multiple turbochargers are run on-engine under conditions designed to cause seal leakage. No significant leakage is allowed during these tests. "Heat Soakback - A turbocharger instrumented with thermocouples is taken beyond maximum operating temperature and shut down hard! Repeat the test four more times and make sure maximum temperatures stay within our strict limits to avoid oil coking or build up inside the center housing. This is particularly critical for high temperature gasoline applications.
(continued)
26
Testing
"Compressor & Turbine Performance - The entire operating range of both the compressor and turbine are mapped on one of Garretts Performance Gas Stands. These test cells are calibrated to strict standards to assure accuracy and consistency. "Compressor & Turbine Blade Frequencies - Garrett has strict requirements for compressor and turbine blade natural frequency. This is critical on large trims where the blade must be stiff enough to withstand potentially damaging vibrations. "Thermal Cycle - A 200-hour endurance test that cycles the turbocharger from low temperature to glowing red every 10 minutes. To ensure a long turbo life, no cracking of the turbine housing or distortion of the heat shroud are allowed. "Rotor Inertia - A measurement made to document the rotational inertia of Garretts compressor and turbine wheels. Garretts products are known for their high flow / low inertia characteristics. "Shaft Critical Speed - An analytical test that ensures that destructive shaft critical speeds are well out of the turbocharger operating range. For example, large wheels may require a large shaft diameter to avoid the shaft bending critical speed. "Compressor Fatigue - Garrett will not sell compressor or turbine wheel castings that have not passed a strict test to failure cyclic fatigue test. Garrett runs tests on a regular basis to ensure quality and to constantly improve our products. "Turbo Vibration - The entire turbocharger is vibrated on Garretts large shaker table. Vibration levels are monitored to ensure product durability.
27
Statement of Warranty
YOU, THE BUYER, MAY CHOSE IN YOUR SOLE DISCRETION TO RESELL OR USE GARRETT ENGINE BOOSTING SYSTEMS PERFORMANCE PRODUCTS FOR RACING VEHICLES, WHICH ARE INHERENTLY DANGEROUS AND MAY NEVER BE DRIVEN ON A PUBLIC ROADWAY. GARRETT, THE SELLER, DISCLAIMS ANY AND ALL LIABILITY ASSOCIATED WITH RACING VEHICLES AND COMPONENTS. ACCORDINGLY, NOTWITHSTANDING ANYTHING TO THE CONTRARY CONTAINED IN BUYER'S PURCHASE ORDER TERMS AND CONDITIONS OR SELLER'S SALES ORDER TERMS AND CONDITIONS OR OTHER PUBLICATIONS (INCLUDING THIS CATALOGUE), OR CONTAINED IN ANY OTHER AGREEMENTS BETWEEN THE PARTIES, SELLER MAKES NO REPRESENTATION OR WARRANTY WHATSOEVER, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OR REPRESENTATION AS TO CONDITION, MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR SUITABILITY AS TO ANY OF THE ITEMS LISTED IN THIS CATALOGUE. ALL ITEMS ARE BEING SOLD ON AN "AS IS" BASIS. IN NO EVENT SHALL SELLER OR ANY OF ITS AFFILIATES BE LIABLE IN CONNECTION WITH PRODUCTS LISTED IN THIS CATALOGUE FOR SPECIAL, PUNITIVE, INCIDENTAL OR CONSEQUENTIAL DAMAGES, INCLUDING LOST PROFITS, TO THE FULL EXTENT THESE DAMAGES MAY BE DISCLAIMED BY LAW. YOU MAY HAVE OTHER RIGHTS THAT DIFFER FROM STATE TO STATE.
Use of compressor maps and turbine maps
Proprietary Notice: This document contains proprietary information, and such information may not be reused or disclosed to others for any purpose, or used for manufacturing without written permission from Honeywell Inc.
28
Project Vehicles
Appendix
Appendix
Appendix A
Turbo Terms
A/R- A/R describes a geometric property of all compressor and turbine housings. Increasing compressor A/R optimizes the performance for low boost applications. Changing turbine A/R has many effects. By going to a larger turbine A/R, the turbo comes up on boost at a higher engine speed, the flow capacity of the turbine is increased and less flow is wastegated, there is less engine backpressure, and engine volumetric efficiency is increased resulting in more overall power. CHRA- center housing rotating assembly The CHRA includes a complete turbocharger minus the compressor, turbine housing, and actuator. Clipped Turbine Wheels- When an angle is machined on the turbine wheel exducer (outlet side), the wheel is said to be clipped. Clipping causes a minor increase in the wheels flow capability, however, it dramatically lowers the turbo efficiency. This reduction causes the turbo to come up on boost at a later engine speed (increased turbo lag). High performance applications should never use a clipped turbine wheel. All Garrett GT turbos use modern unclipped turbine wheels. Free-Float- A free floating turbocharger has no wastegate device. This turbocharger cant control its own boost levels. For performance applications, the user must install an external wastegate. GT- The GT designation refers to Garretts state-of-the-art turbocharger line. All GT turbos use modern compressor and turbine aerodynamics which represent huge efficiency improvements over the old T2, T3, T3/T4, T04 products. The net result is increased durability, higher boost, and more engine power over the older product line. Wastegate- A wastegated turbocharger includes an integral device to limit turbo boost. This consists of a pneumatic actuator connected to a valve assembly mounted inside the turbine housing. By connecting the pneumatic actuator to boost pressure, the turbo is able to limit its maximum boost output. The net result is increased durability, quicker time to boost, and adjustability of boost.
TrimTurbine = (Exducer Diameter) X100 (Inducer Diameter) 2
2
On-Center Turbine Housings- On-center turbine housings refer to an outdated style of turbine housing with a centered turbine inlet pad. The inlet pad is centered on the turbos axis of rotation instead of being tangentially located. Using an on-center housing will significantly lower the turbines efficiency. This results in increased turbo lag, more backpressure, lower engine volumetric efficiency, and less overall engine power. No Garrett OEMs use on-center housings. Trim- Trim is an area ratio used to describe both turbine and compressor wheels. Trim is calculated using the inducer and exducer diameters. As trim is increased, the wheel can support more air/gas flow. Use these formulas when calculating trim:
TrimCompressor = (Inducer Diameter) X100 (Exducer Diameter) 2
2
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performance products

Applications & Distributors

The Garrett Performance Products Catalog

* See Turbo Terms in Appendix

Applications & Distributors

S4, A6 Buick Grand National

Corvette, Camaro, Light Duty Truck 5.9L Light Duty Truck

6.9L, 7.3L - Light Duty Truck Focus Mustang

Honda Mazda Nissan

Civic Protg 300ZX, Sentra, 240

911, 944 Imprenza WRX

Pickup, 4 Runner, Supra 1.8L - Golf, Passat, Jetta, Beetle

Ford, GM & Dodge Trucks

Audi & Volkswagon

GT35 GT32 GT20 GT22 GT15 GT12

GT12 41mm, 50 trim, 0.33 A/R

Pressure Ratio (t/t) P2c/P1c

GT12, 72 trim, 0.39 A/R

Turbine 59% Max Efficiency

Corrected Air Flow (lbs/min)

Pressure Ratio (T/s) P1T /P2S

Horsepower 50 - 130 Displacement .4L - 1.2L

GT15 45mm, 60 trim, 0.48 A/R

GT15, 72 trim, 0.35 A/R

Pressure Ratio (t/t) P2c/P1c

Turbine 59% Max Efficiency

Corrected Air Flow (lbs/min)

Pressure Ratio (T/s) P1T /P2S

Horsepower 100 - 220 Displacement 1.0 - 1.6L

GT20 56mm, 55trim, 0.53 A/R

Pressure Ratio (t/t) P2c/P1c

2 1.8 1.6 1.4 1.2

76% 74% 72% 70% 68% 65%

GT20, 72 trim, 0.46 A/R

Corrected Air Flow (lbs/min)

Max Efficiency 66%

Pressure Ratio (T/s) P1T /P2S

Horsepower 140 - 260 Displacement 1.4 - 2.0L

Pressure Ratio (t/t) P2c/P1c

2.6 2.4 2.2 2

GT22, 72 trim, 0.67 A/R GT22, 72 trim, 0.56 A/R

1.6 1.4 1.2

Corrected Air Flow (lbs/min)

Max Efficiency 72%

Pressure Ratio (T/s) P1T /P2S

CHRA 451298-6 451298-9

Wh Dia 52mm 59.41mm

A/R 0.51 0.42

Wh Dia 50.3mm 50.3mm

A/R 0.67 0.56

Type Wastegated Free Float

Wastegated Free Float

GT32 71mm, 52 trim, 0.52 A/R

Pressure Ratio (t/t) P2c/P1c

2.8 2.6 2.4

2.2 2 1.8 1.6 1.4 1.2 1

GT32, 73 trim, 0.78 A/R GT32, 73 trim, 0.69 A/R

Corrected Air Flow (lbs/min)

Max Efficiency 68%

Pressure Ratio (T/s) P1T /P2S

Free Float Wastegated

Pressure Ratio (t/t) P2c/P1c

2.8 2.6 2.4